In modern production, process automation plays a crucial role in creating cost-efficient and high quality products. High precision is particularly important when assembling complex and flexible components such as cable harnesses. The precise handling of flexible components is extremely challenging, as they are easily deformed and their position can change. To make this process efficient and reliable, non-contact position detection is required so that robots can precisely detect cables and insert them into the connector housing.

Real-time synchronisation

High-resolution laser profile scanners from Micro-Epsilon’s scanCONTROL 3010-200 series have proven effective for these tasks. The sensors measure the position and geometry of the cables in real time so that the robot can grip them securely and fit them in the designated slots. Another building block for successful implementation is software, which processes the measurement data and synchronises it immediately with the movement of the robot. In this way, the manufacturer can ensure that the robot determines the exact pick-up point and inserts the cables precisely into the intended connectors – a decisive advantage for cable harness assembly automation.

Real-time synchronisation between the sensor and the robot ensures precise position detection and reliable processing. It is also a flexible automation cell that can be reprogrammed at any time without the need for complex mechanical modifications. The combination of standard components creates an economical solution that replaces cost-intensive, rigid special machines and significantly increases production efficiency.

Laser scanners for every measurement task

The wide selection of sensor models and measuring ranges now available in the scanCONTROL range of laser scanners enable engineers to solve every profile measurement task. Smart laser scanners with integrated data processing allow users to solve common measurement applications without the need for external data processing. For more complex applications, sensors with programmable software are available.

With Micro-Epsilon’s Configuration Tools software, more than 40 measurement programs with a total of more than 90 evaluations are available. The programs are transferred to the SMART sensor, which performs the measurement, evaluation and output in standalone mode.

Fast, high precision 2D/3D measurements

The scanCONTROL 30×0 series is among the highest performing profile sensors in terms of their size, accuracy and measuring rate. They provide calibrated 2D profile data with up to 7.37 million points per second. A profile frequency of up to 10kHz enables precise profile measurements in dynamic high speed processes.

The high resolution sensor matrix offers a resolution of 2,048 points with an ultimate point distance of just 12µm, enabling extremely fine details to be detected reliably. The sensors are available with either blue or red laser diodes.

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An increasing number of industrial applications require reflective surfaces to be recognised and measured. For example, in electronics manufacturing, smartphone production and in the automotive industry when producing mirrors or checking for paint defects on finished car bodies. In order to detect a fault or defect on these surfaces, OEMs require high precision measuring systems that detect deviations in the surface structure to sub-micrometre accuracies.

For all these fields of application, Micro-Epsilon has developed the reflectCONTROL sensor series, which is based on the deflectometry measuring principle. Here, the sensor displays a sinusoidal striped pattern via a monitor, which is reflected into the sensor’s cameras via the surface of the object being measured, for example, a car body. The resulting phase images can be used to calculate ‘kernel’ images based on the measured variables of base intensity, amplitude and curvature. Deviations on the surface are detected, processed by the software and displayed in the reflectivity and curvature images.

High resolution measuring system

The reflectCONTROL Automotive measurement system from Micro-Epsilon (also known as PSS 8005-D) has a measurement area of 367.5 mm x 823.4 mm. The sensors measure the smallest of defects at a resolution of 185 µm and operate with a measurement data acquisition time of 400 ms. The supply voltage is 24 V DC with a power consumption of less than 200 W.

This high precision, high resolution benefits leading vehicle manufacturers in paint defect inspection. In the past, these companies relied on light tunnels where skilled workers would use fixed lighting systems and cameras to detect defects in the paintwork. Alternatively, systems whereby the car body would move past static sensors on a conveyor belt were also used to detect defects. However, both options are very error-prone for different reasons.

This is why car manufacturers now rely on measuring systems such as reflectCONTROL, where the vehicle chassis is brought into a fixed position. The sensors are attached to robotic arms and move across the bodywork. Micro-Epsilon chose this method because it achieves the lowest error rate and the required cycle times – the time that elapses between the inspection of two vehicles – can be met.

Two to four robot arms, each with an integrated sensor, work at each inspection station – allowing the entire chassis to be measured. For very short cycle times, two stations with four robots each have proved successful – but Micro-Epsilon can offer solutions for all desired cycle times.

In order to accelerate and decelerate the robot arm sufficiently, it was necessary to keep the total weight of a sensor below 50 kg, which Micro-Epsilon achieved using a carbon housing. This also increases the robustness of the overall system and protects the robot arm, which further extends its service life.

Defect detection and automatic processing

With light tunnels, car manufacturers achieved a defect coverage of around 60% in the past meaning around 40% of defects were left undetected! With reflectCONTROL, fault coverage of almost 100% is now possible. This high fault coverage is due to outstanding defect detection and automatic processing.

First, the vehicle is measured from one measuring position to the next and any defects found are projected back onto the vehicle surface. A defect can be localised at +/- 3 mm on the vehicle surface. 3D features such as height, depth and volume are added to each defect using 3D reconstruction, which is unique on the market. All collected data is saved in an XML file and so is available to the vehicle manufacturer at any time.

Once the defect has been detected and localised, automatic processing can begin, which Micro-Epsilon implements together with its partner companies ASIS and Virtek Vision. This is carried out using additional robots with active force control, each equipped with a dual-mounted sanding and polishing head. A robot first grinds off the defect and then polishes it. Used sanding sheets and polishing sponges are removed at changing stations and new ones are picked up automatically.

New polishing sponges are automatically prepared with polishing agent. The polishing agent is supplied directly to the robot using a clever cartridge principle. Using a laser marking system from Virtek Vision, the defect is then marked as machined without contact by projecting light onto the body. If required, additional defects can also be displayed via the projection, which must be reworked manually. The system knows at all times which robot is currently processing which points or which defects have already been processed.

The most important prerequisite for automatic processing is the detailed database that Micro-Epsilon can provide with reflectCONTROL. This enables OEMs to optimise their production, identify error chains and intervene at an early stage if errors occur. This saves OEMs time and costs in production.

Another important innovation is the classification of data. This can be used to automate the processing of errors. Classification means recognising the type of defect, for example, whether it’s a crater, inclusion or defect from the sub-surface. The customer also has access to 3D data so they can access the exact dimensions of the defect at any time and initiate extensive analyses. As all data can be transferred to the company’s internal Q-System at any time, alarm functions can be set up and faults communicated at the appropriate point.

System learns automatically

More data can be derived from the 3D image and used to determine a wide range of variables. The system can also independently define new defect classes. Due to the large database, the system can also be used for audits. The labelled data is also used to train the underlying AI algorithms.

All data is available to the OEM in a file and can be read into the standard higher-level Q systems. This means that the data can also be visualised using established tools. The system learns from all the data it collects and therefore becomes increasingly ‘intelligent’. This saves the OEM time when working through errors, and the data can also be used to set up early warning systems to detect and eliminate error chains at an early stage. For example, warning thresholds can be created when certain numbers of defects are exceeded. In addition, heat maps can be used to find error hotspots and draw conclusions about certain upstream processes.

In addition to automatic processing with partner companies, Micro-Epsilon can perform an appearance evaluation that enables a structural evaluation of the surface. The existing paint structure is broken down into its spectral components. The components are summarised in different frequency ranges, for example, short or long wave, ie which short and long waves are contained in the structure of the surface, as no surface is perfectly smooth.

It is important for car manufacturers to maintain certain appearance values on a car body. Automated cells, end-of-line cells or aqua cells are normally used for this purpose. A vehicle is inserted into this and viewed by a robot with a scanner. The robot moves to the various positions and measures the appearance directly over the surface. This takes around 20 minutes in total – so a maximum of three vehicles can be measured per hour.

With the system from Micro-Epsilon, the appearance can be evaluated on the basis of the existing images without additional hardware. This saves time and costs for the OEM. In addition, any number of measurement positions can be defined, which basically corresponds to a full-surface appearance measurement. The number of vehicles is also not limited. The evaluation can also be output for each body. This enables the OEM to recognise trends and set and issue alarm signals – before major damage occurs.

Recognise and avoid defects

With reflectCONTROL, defects in reflective surfaces can be detected and classified almost 100%. The system is superior to conventional light tunnels and static systems, particularly in the field of paint defect inspection in automotive production. Due to the large database, manufacturers of automatic processing systems are able to assign the correct processing recipes to the defects. This reduces unnecessary defect handling and therefore saves the OEM resources and costs.

Micro-Epsilon offers reflectCONTROL as a complete system from error detection to the analysis of 3D data via the database. ReflectCONTROL is developed and manufactured at Micro-Epsilon sites in Germany and Austria. Micro-Epsilon can implement reflectCONTROL at production sites worldwide – due to its international subsidiaries.

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The optoNCDT 1220 series of laser triangulation sensors are used for precise, high resolution distance, displacement and position measurements in industrial automation. Due to their lightweight, compact design with integral controller, the sensors are ideal for measurement tasks in factory automation, as well as integration into machines. Typical application areas include electronics manufacturing, robotics and 3D printing, as well as machine building and renewable energies.

The optoNCDT range of laser sensors from Micro-Epsilon offers various interface options, including RS422, EtherCAT, EtherNet/IP and Profinet. The optoNCDT 1220 is the first in the optoNCDT family to come with IO-Link integrated. IO-Link enables continuous communication between sensor and control unit. Data collected by devices with IO-Link can be easily transferred to a cloud or higher-level systems via an IO-Link master. Simplified installation, faster commissioning, as well as less programming effort due to predefined function modules, means reduced costs for customers.

In addition, troubleshooting is facilitated by comprehensive consistent diagnostic information down to sensor level. Sensor replacement during operation is also easier due to automatic re-parameterisation.

IO-Link is a fieldbus-independent interface that is standardised worldwide according to IEC 61131-9. IO-Link can be integrated into all common fieldbus and automation systems. Connection to the IO-Link master is via a standard 4-pin M12 connector located on the end of a short, 0.3m, pigtail cable from the sensor.

Micro-Epsilon says the optoNCDT 1220 series sets new standards in displacement and distance measurements for industrial automation applications. The powerful sensor features the most important basic settings, functions and data output options. This lean range of features is mirrored in the sensor’s favourable entry-level price, which makes the sensor attractive, particularly for OEM projects where high sensor volumes are required, and where fast integration, ease of use and space-saving solutions are necessary.

The sensor’s Active Surface Compensation (ASC) feature enables reliable control of the distance signal regardless of target colour or brightness. Ready to use straight out of the box, the sensor is easily integrated without having to make any further settings. An intuitive web interface enables easy set up and configuration, if required.

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The new office will look to provide customers in the Republic of Ireland with local support, sales and precision test facilities. In addition to serving the Republic of Ireland, the company will also be responsible for sales, service and support of customers in Northern Ireland.

Chris Jones, Managing Director of Micro-Epsilon UK and Ireland comments: “Manufacturing is one of the high performing segments of the Irish economy, with clusters of world class manufacturing operations in sectors such as electronics, food production, medical technology and biopharmaceuticals.

“Our new premises in Dublin, which will be closely supported and facilitated by the Micro-Epsilon UK team, will allow us to better serve our customer base in Ireland with faster response times, a better quality service and the ability to place orders directly with an Irish company.”

Ireland’s level of employment in high-technology manufacturing, as a share of total employment, is now the highest in the EU, with 29% of manufacturing jobs in high technology sectors (source: Manufacturing in Ireland – IBEC). This is four times the EU average. Overall, there are 260,000 people employed in the Irish manufacturing sector, accounting for more than 12% of total employment in the economy.

Jones continues: “The high-tech nature of the manufacturing industry in Ireland perfectly matches our own product portfolio of advanced sensor and measurement solutions. We can now provide machine builders and systems integrators based in Ireland with improved local sales, test and support services.”

Robert Redmond adds: “I am incredibly grateful to begin this journey with Micro-Epsilon Ireland. As an industry leader in precision measurement systems, Micro-Epsilon is at the forefront of innovation, and I am truly honoured to be part of the team bringing their cutting-edge products to the Irish market.

“With an extensive range of sensor solutions that address a diverse array of applications, every day presents new challenges and opportunities, something that excites me greatly. I look forward to delivering effective solutions that not only provide real value to our customers but also foster strong, lasting relationships along the way.”

Micro-Epsilon Ireland will be offering customers access to the full product portfolio including 1D, 2D and the latest 3D sensor technology for displacement measurement along with the IR temperature products and colour inspection sensors.

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Sensors have a decisive influence on efficiency and accuracy in robot-controlled production processes. They help robots to perform tasks such as assembly, inspection and quality control quickly and reliably, as they act as sensory organs for the robot. The use of robots reduces production costs and waste, while increasing product quality.

Sensor specialist Micro-Epsilon serves almost all industries with its broad sensor portfolio and supports countless manufacturing processes.

Calibration of robot axes

Micro-Epsilon sensors are already being used in the calibration of robot axes. To achieve fully automatic, independent calibration of robot cells, scanCONTROL laser scanners and optoNCDT laser triangulation sensors are used. These optical sensors enable continuous monitoring and restoration of the production process at the push of a button. The sensors are placed directly on the robot and measure onto a plate with reference targets. This system is operated together with special software from teconsult.

Various Micro-Epsilon sensors can be directly integrated into the software. In addition, the solution can perform automated measurements, tests or corrections of the robot kinematics, the robot gripper and the periphery of the robot cell. The sensor technology is permanently integrated into the robot cell or used as a portable service tool.

3D scan before laser cladding

In laser cladding, a melt pool is created on the surface of the component and a new, pore-free layer is created by adding a new and powdered filler material. The core task of the sensors is to detect free forms and shape deviations before laser processing. A laser scanner from Micro-Epsilon’s scanCONTROL series scans the components. If required by the component geometry, this is performed from several directions.

Regardless of the reflection properties of the material, the sensor constantly provides reliable measurement values. The raw data is transferred directly to the customer’s software, merged into a 3D model and finally used for the path planning of the laser welding head. In addition, the nozzle can be placed at the correct distance from the surface and then guided along the calculated path. The result is a new, even and full surface. In contrast to a camera solution, laser profile scanners enable a 3D model to be created and are surface-independent in terms of contrast.

The higher precision, as well as the various integration and processing possibilities of the acquired measurement data, also offer significant advantages in this application. Compared to tactile measurement, the cycle time required for non-contact measurement is also considerably shorter.

Print head positioning for concrete printing

Micro-Epsilon laser profile scanners are used for process control in concrete printing. These compact and lightweight scanners can be mounted directly on a robot and measure the concrete strand immediately after application.

Due to large measuring ranges and the integrated signal calculation and evaluation, the complete strand is measured quickly and precisely and the evaluated measurement signal is transmitted directly to the control system.

Precise windshield assembly

In the automotive industry, there are measurement tasks that require simultaneous detection of several measurement values or three-dimensional detection of measuring objects within short cycle times. For example, when installing a vehicle windshield, a scanCONTROL laser line sensor detects detailed distance values in all axes. In the installation process, the sensor is mounted onto the robot, which fits the window into the vehicle.

When the windshield is placed on the car, the scanner detects the complete profile and vicinity of the windshield while all necessary values are determined with a single run in quick time. It can be determined whether the windshield is placed straight and centred or whether it fits perfectly in every plane. The result, in this case gap and flushness, are directly generated in the sensor head and output to the PLC.

Adhesive bead inspection

Another measurement task concerns the adhesive, which has already been applied before the windshield is fitted into the chassis. Therefore, a laser scanner is directly mounted onto the robot that applies the adhesive beading. Here, the sensor moves along the adhesive bead to create a 3D image. It reveals whether the adhesive quantity is sufficient, whether it is applied evenly and whether the bead is applied in the correct places.

All detected measurement values are stored separately. If an error occurs in the process at a later point in time, these measurement values can be used for analysis purposes.

Strengths of the optical sensors

The strengths of the scanCONTROL laser scanners and optoNCDT laser triangulation sensors lie in their compact design, which means they can be easily integrated into robot-based applications, even where space is limited. Due to robust cabling, the sensors are suitable for the extreme rotational and torsional movements on the robot arm. They also have an integrated, highly sensitive receiver matrix, which enables measurements on almost all industrial materials, largely independent of surface reflection. Real-time quality control enables immediate intervention in production control.

There is a choice of sensors with a red laser diode or with the patented Blue Laser Technology, which is generally used when the red laser light reaches its limits. This is the case, for example, with organic materials, wood, semi-transparent materials or red-hot glowing metals. The blue laser light can be focused more sharply on certain surfaces and enables high precision measurements there too.

For applications where harsh environmental conditions prevail, Micro-Epsilon offers special accessories that protect the sensors. For welding applications, for example, a special housing is available with interchangeable protective screens. A special compressed-air purge system protects the optical components from dust.

Measuring principle of laser scanners

The laser profile scanner uses the triangulation principle for two-dimensional profile acquisition. It emits a laser beam that is expanded into a laser line. This hits the measuring object. The laser light is reflected by the object surface and projected onto a highly-sensitive receiving matrix in the sensor.

In addition to distance information (z-axis), the controller also uses this camera image to calculate the position along the laser line (x-axis). These measured values are then output in a two-dimensional coordinate system that is fixed with respect to the sensor. In the case of moving objects or a traversing sensor, it is therefore possible to obtain 3D measurement values.

Measuring principle of laser triangulation sensors

The laser triangulation principle is based on a simple geometric relationship. A laser diode transmits the laser beam onto the measuring object. A lens focuses the reflected rays onto a CCD/CMOS array. The distance to the target object is determined via a triangular relationship between the laser diode, the measurement point on the object and the image on the CCD line. The measurement resolution reaches a fraction of a micrometer.

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The software is compatible with all 3D sensors in the Micro-Epsilon portfolio, including surfaceCONTROL for geometry, shape and surface inspection of matt objects; reflectCONTROL for measurement of shiny, reflective surfaces, and scanCONTROL sensors laser scanners for precise, inline 3D measurements.

3DInspect is designed for ease while offering a wide range of functions for analysing and measuring captured data. These include parameter setting of the sensors, alignment of point clouds and the selection of relevant objects, filters for smoothing and optimising point clouds, as well as calculation programs for height, radius and determining flatness and distances between points and angles. The software is able to find a target based on its contour and readjust it to allow further inspection to be made.

The 3DInspect software concept offers four steps to obtaining results:

• Data acquisition – ensuring that the sensor and the target are correctly aligned aided by the ‘Display Image’ data. The data is then captured and processed into the software.
• Data pre-processing – realigning of the captured data so that it is in line with the XYZ coordinate system.
• Evaluation – the data can now be evaluated and various processes can be set up to inspect.
• Transfer of data – the data can now be output from the software. This can be done in a number of different ways depending on the user’s configuration and set up. Available output formats are UDP, TCP and Modbus, where 3DInspect acts as the server. With additional modules, control and measured value output are also possible via Profinet and Ethernet/IP.

Glenn Wedgbrow, business development manager at Micro-Epsilon UK comments: “For those system integrators with their own 3D processing software such as HALCON or similar, we offer our documented 3D Software Development Kit [SDK] with examples for various programming languages , so that they can create their own solutions to applications. For end users who do not have the capability to write their own software code, we offer the 3DInspect software solution.”

In addition to the standard version of 3DInspect, the ‘Automation’ function extension supports automated production processes. Video tutorials explain the software application and its features. As the software is constantly being developed, it is always up to date and every new release offers further useful functions. A comprehensive SDK is available for third party and custom image processing solutions. This is based on the GigE Vision and GenICam industry standards, including numerous function blocks.

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The triangulation sensor, which is mounted on a Fanuc robot end effector, intricately measures the contours – the ‘bend’ and ‘twist’ – of the fishplates to ensure they are within the required manufacturing tolerances. The automation cell then places the fishplates into a Mynx 5400 to be machined.

One of the fastest growing machine tool companies in the UK, Mills CNC is the sole provider of Doosan Machine Tools within the nation and has machines to suit all the manufacturing sectors including aerospace and defence, power generation, motorsport, oil and gas, medical, automotive and general precision component manufacture. The company’s reputation is built on the quality, reliability and performance of the Doosan machine tools it sells.

Established in 2018, Mills CNC Automation was created to project Mills CNC and its customers businesses forward. Mills CNC saw automation as key to increasing manufacturing productivity and output for all customers, both old and new. The division, which is located at Mills CNC’s Technology Campus facility in Leamington Spa, has two principal specialisms, Industrial Robots and Collaborative Robots.

Chris Ingham, controls and systems engineer at Mills CNC Automation comments: “At the Technology Campus, we’ve developed a number of automation systems and machine tool demonstrations for our customers to view. We are currently testing and commissioning an automation system for a customer who needs to inspect railway fishplates manufactured by a hot rolling mill. The project began in late 2020 and the inspection system uses a laser triangulation sensor from Micro-Epsilon.”

Fishplates are metal bars that are bolted to the end of two rails to join them together in a railway track. The hot rolling mill produces the high ductile steel fishplates in four different product groups that vary in length from 0.5m up to 1.0m. Mills CNC Automation has custom designed, and built, a fully automated machine tool pick-and-place system for inspecting the fishplates.

Easy integration was key

The optoNCDT 1750 laser triangulation sensor from Micro-Epsilon is mounted on a robot end effector in between two magnetic grippers. The laser sensor measures the fishplate in eight different positions (on average) and outputs this data via the Micro-Epsilon IF2030 EtherNet I/P module into the Fanuc robot controller.

This data is then utilised by Mills CNC’s own custom analysis software with the results displayed on the machine tool HMI. The data is used to verify that the fishplates are within tolerance in all three planes, including whether ‘bend’ and ‘twist’ tolerances have been exceeded.

As Chris Ingham explains: “If the measurement data shows that a fishplate is out of tolerance, the part is rejected before machining and returned to the rolling mill. The fishplates need to be within a tolerance of 2mm over a length of one metre, but we needed a sensor that was reliable and capable of communicating with our Ethernet I/P network. These factors, as well as a favourable price-performance ratio, were critical for us when searching for a suitable sensor solution.”

The optoNCDT 1750 is a laser triangulation sensor with integrated controller that is perfect for mounting on a robot end effector. It is also suitable for high speed distance, displacement and position measurements in a wide range of applications, including automation, machine building, electronics production, packaging, automotive and process manufacturing. Mills CNC is using a sensor with a measuring range of 750mm.

The optoNCDT 1750 series is also available in measuring ranges from 2mm up to 750mm. The sensor’s measuring rate is continuously adjustable up to 7.5kHz and can be individually adapted to suit each measurement task. Data output is via analogue or digital RS422 interface. Due to the Advanced Real Time Surface Compensation (A-RTSC) feature, the sensor operates almost regardless of the target material and colour. The exposure time or amount of light produced by the laser sensor is optimally matched to the reflection characteristics of the target surface, which enables reliable measurements even of difficult, changing surfaces.

The IF2030 module from Micro-Epsilon converts the sensor’s RS422 output for integration to industrial networks and is available for Profinet or Ethernet/IP. The IF2030 EtherNet I/P interface module is a single channel system that is compatible with Micro-Epsilon sensors that output data via their RS422 or RS485 interface. The interface module supports data rates up to 4 MBaud and can be installed in switching cabinets via a DIN rail.

“When I first contacted Micro-Epsilon, their application know-how and experience was evident. Once I had fully explained our application to Micro-Epsilon, they advised me on which type of measurement technique would be most suitable, in this case laser triangulation. From there, they advised me on which sensor product would best meet our needs. The only aspect of the sensor solution that we decided to carry out ourselves was to build a custom enclosure for the sensor that provides additional protection from machine tool coolant mist,” says Chris Ingham.

He concludes: “The sensor is performing well and is providing reliable measurement data. During the machine test and commissioning phase, the customer has been sending us different groups of parts to inspect and so we’ve really been able to put the sensor through its paces. We’ve been very impressed with the sensor and technical support when we’ve required it. We look forward to working with Micro-Epsilon again in the future.”

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The new compact optoNCDT 1750 laser triangulation sensor succeeds the optoNCDT 1700 series of laser sensors. The optoNCDT 1750 is a powerful sensor that provides a variety of new features combined with higher measuring rates, robustness and reliability.

Based on an innovative web interface, the optoNCDT 1750 is incredibly easy to use and set up without requiring any additional operating software. The settings for the measurement task can be quickly selected using application-specific, predefined presets. These are available to suit a wide variety of materials and surface types, including metals, plastics and organics. These presets enable rapid, straightforward set up and help to optimise the sensor for specific tasks.

The measuring rate is continuously adjustable up to 7.5kHz and can be individually adapted to suit each measurement task. Peak selection and suppression of interference peaks enable reliable measurements on coated materials, measurement objects located behind glass and on film-sealed components. Data output is via analogue or digital RS422 interface. Furthermore, the optoNCDT 1750 provides two switching outputs that are controllable.

Due to its compact design with integral controller, the optoNCDT 1750 is also extremely versatile in terms of its potential applications, while simplifying installation into restricted spaces on industrial plant, machines, automated production lines and robots.

Due to the Advanced Real Time Surface Compensation (A-RTSC) feature, the sensor operates almost regardless of the target material and colour. The exposure time or amount of light produced by the laser sensor is optimally matched to the reflection characteristics of the target surface, which enables reliable measurements even of difficult, changing surfaces.

New evaluation software algorithms and enhanced components provide even higher measurement accuracy and dynamics. High performance optics generate a small spot size onto the target, which enables very small objects to be measured accurately and reliably.

Chris Jones, managing director at Micro-Epsilon UK comments: “The combination of enhanced performance and a wide range of features result in a new laser sensor that really is at the top of its performance class. Due to its compact design with integral controller, the optoNCDT 1750 is also extremely versatile in terms of its potential applications, while simplifying installation into restricted spaces on industrial plant, machines, automated production lines and robots.”

The optoNCDT 1750 series is available in measuring ranges from 2mm up to 200mm. Maximum linearity is 1.6µm.

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The application of the adhesive beading is performed using a robot positioned on either side of the production line. Two optoNCDT 1700 laser sensors from Micro-Epsilon are used for precise positioning of these robots. The sensor and nozzle for applying the adhesive beading are located on the end effector. The sensors measure the position of the roof channel on the vehicle body. Using the calculated data, the nozzle is positioned precisely over the weld seam, enabling error-free application of the PVC seam.

Due to its fast exposure regulation RTSC (Real-Time Surface Compensation) the optoNCDT sensor is used here. The steep transition into and out of the roof channel is measured reliably and without errors using RTSC. As the maximum load capacity of the robots is almost reached with the applicator alone, the sensor must be as compact and lightweight as possible, with high measurement performance and low space requirements. This combination of installation size, weight, accuracy and price were decisive factors in this application.

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The new scanCONTROL BL series offers similar features to Micro-Epsilon’s proven scanCONTROL series of laser profile scanners that use red laser technology. All the controls and electronics are integrated in an extremely lightweight, compact sensor design, enabling the scanners to be installed on robot arms where there may be little space available for mounting. The scanCONTROL BL series offers a range of interfaces and flexible installation options.

Chris Jones, Managing Director at Micro-Epsilon UK comments: “With red-hot glowing objects, a conventional red laser has a high signal interference because it emits the same or very near wavelengths of light as the red laser. This can result in the ‘dazzling’ of red laser profile scanners. However, a blue laser works at a wavelength of 405nm, which is far from the red part of the visible spectrum. This means it is unaffected by the emitted infrared radiation, which is easy to filter, ensuring very stable signals. Similarly, when measuring on transparent or organic materials, due to its shorter wavelength, blue laser light penetrates significantly less into the surface than a red laser, resulting in higher measurement accuracy.”

Laser triangulation principle

Laser profile scanners from Micro-Epsilon operate on the laser triangulation principle for two-dimensional profile detection on different target surfaces. By using special lenses, a laser beam is enlarged to form a static laser line and is projected onto the target surface. A high quality optical system projects the diffusely reflected light of this laser line onto a highly sensitive sensor matrix.

In addition to distance information (z-axis), the controller also uses this camera image to calculate the position along the laser line (x-axis). These measured values are then output in a two-dimensional coordinate system that is fixed with respect to the sensor. In the case of moving objects or a traversing sensor, it is therefore possible to obtain 3D measurement values.

The scanCONTROL BL series is available with measuring ranges up to 265mm in the z-axis (distance/profile height) and up to 143.5mm in the x-axis (laser line length/profile width). Output of measurement data is via Ethernet (UDP, Modbus) or serial interface (RS422, Modbus). In addition, analogue signals or digital switching signals can be output directly to a PLC. Profile frequencies of up to 2,000Hz and a measuring rate of up to 2,560,000 points/sec enable the sensors to be used in high speed applications.

Easy integration and connection to PLCs

The sensors are equipped with a Gigabit Ethernet interface for transferring profile data, as well as a multi-purpose connector for RS422, Digital In (HTL/TTL), power supply and synchronisation. The sensors support Power-over-Ethernet (PoE), which reduces the need for an additional power cable. Configuration of the sensor is carried out using a supplied software programme, which enables the device to be configured to a unique IP address. A Modbus protocol (supported via Ethernet and the RS422 interface) also enables direct connection between the sensor and a PLC.

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